Air Ducting Shroud For Cooling An Air Compressor Pump And Motor

ABSTRACT

A compressor assembly having an air ducting shroud that can direct a cooling air stream from a fan to components of the compressor assembly, such as a pump assembly. The pump assembly can have at least a pump, a motor and a fan. The compressor can be cooled by providing cooling air to a cylinder head of the pump without the cooling air experiencing choking or substantial cooling flow interference from a cooling of the motor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims benefit of the filing date under 35 USC§120 of copending U.S. provisional patent application No. 61/533,993entitled “Air Ducting Shroud For Cooling An Air Compressor Pump AndMotor” filed on Sep. 13, 2011. This patent application claims benefit ofthe filing date under 35 USC §120 of copending U.S. provisional patentapplication No. 61/534,001 entitled “Shroud For Capturing Fan Noise”filed on Sep. 13, 2011. This patent application claims benefit of thefiling date under 35 USC §120 of copending U.S. provisional patentapplication No. 61/534,009 entitled “Method Of Reducing Air CompressorNoise” filed on Sep. 13, 2011. This patent application claims benefit ofthe filing date under 35 USC §120 of copending U.S. provisional patentapplication No. 61/534,015 entitled “Tank Dampening Device” filed onSep. 13, 2011. This patent application claims benefit of the filing dateunder 35 USC §120 of copending U.S. provisional patent application No.61/534,046 entitled “Compressor Intake Muffler And Filter” filed on Sep.13, 2011.

INCORPORATION BY REFERENCE

This patent application incorporates by reference in its entirety U.S.provisional patent application No. 61/533,993 entitled “Air DuctingShroud For Cooling An Air Compressor Pump And Motor” filed on Sep. 13,2011. This patent application incorporates by reference in its entiretyU.S. provisional patent application No. 61/534,001 entitled “Shroud ForCapturing Fan Noise” filed on Sep. 13, 2011. This patent applicationincorporates by reference in its entirety U.S. provisional patentapplication No. 61/534,009 entitled “Method Of Reducing Air CompressorNoise” filed on Sep. 13, 2011. This patent application incorporates byreference in its entirety U.S. provisional patent application No.61/534,015 entitled “Tank Dampening Device” filed on Sep. 13, 2011. Thispatent application incorporates by reference in its entirety U.S.provisional patent application No. 61/534,046 entitled “CompressorIntake Muffler And Filter” filed on Sep. 13, 2011.

FIELD OF THE INVENTION

The invention relates to a compressor for air, gas or gas mixtures.

BACKGROUND OF THE INVENTION

Compressors are widely used in numerous applications. Existingcompressors can generate a high noise output during operation. Thisnoise can be annoying to users and can be distracting to those in theenvironment of compressor operation. Non-limiting examples ofcompressors which generate unacceptable levels of noise output includereciprocating, rotary screw and rotary centrifugal types. Compressorswhich are mobile or portable and not enclosed in a cabinet or compressorroom can be unacceptably noisy. However, entirely encasing a compressor,for example in a cabinet or compressor room, is expensive, preventsmobility of the compressor and is often inconvenient or not feasible.Additionally, such encasement can create heat exchange and ventilationproblems. There is a strong and urgent need for a quieter compressortechnology.

When a power source for a compressor is electric, gas or diesel,unacceptably high levels of unwanted heat and exhaust gases can beproduced. Additionally, existing compressors can be inefficient incooling a compressor pump and motor. Existing compressors can usemultiple fans, e.g. a compressor can have one fan associated with amotor and a different fan associated with a pump. The use of multiplefans adds cost manufacturing difficulty, noise and unacceptablecomplexity to existing compressors. Current compressors can also haveimproper cooling gas flow paths which can choke cooling gas flows to thecompressor and its components. Thus, there is a strong and urgent needfor a more efficient cooling design for compressors.

SUMMARY OF THE INVENTION

In an embodiment, the compressor assembly disclosed herein can have afan; a pump assembly; an air ducting shroud which directs cooling air toa member of the pump assembly and which is adapted to dampen a noisefrom the pump assembly; and a sound level having a value of 75 dBA orless when the compressor is in a compressing state.

The compressor assembly can have an air ducting shroud which encases atleast a portion of the fan. The compressor assembly can have an airducting shroud which encases at least a portion of a motor of the pumpassembly. The compressor assembly can have an air ducting shroud whichhas a conduit which directs a cooling air flow to a cylinder head of thepump assembly. The compressor assembly can have an air ducting shroudwhich directs a cooling air flow to at least a portion of a motor of thepump assembly. The compressor assembly can have an air ducting shroudwhich directs a cooling air flow to at least a portion of a pump of thepump assembly. The compressor assembly can have an air ducting shroudhaving at least one partition which directs a cooling air flow.

The compressor assembly can have an air ducting shroud having a conduitadapted to direct a cooling air flow to a cylinder head of the pumpassembly. The compressor assembly can have an air ducting shroud whichdirects cooling air to at least a portion of a cylinder of the pumpassembly. The compressor assembly can have an air ducting shroud whichencases a motor and directs a first cooling air flow to a first statorcoil of a motor and which directs a second cooling air flow to a secondstator of a motor and a third cooling air flow to a cylinder head of thepump assembly.

The compressor assembly can have a heat transfer rate from the pumpassembly having a value in a range of 60 BTU/min or greater when thecompressor is in a compressing state.

The compressor assembly can have a cooling air flow rate having a valueof 50 CFM or greater when the compressor is in a compressing state.

The compressor assembly can have a motor of the pump assembly, with amotor efficiency which is greater than 45 percent.

In an aspect, the compressor assembly can be cooled by a method havingthe steps of: providing a fan; providing a pump assembly; cooling thepump assembly with at least a portion of a cooling air flow provided bythe fan when the compressor is in a compressing state; and operating thecompressor at a sound level of less than 75 dBA.

The method of cooling a compressor assembly can also have the steps of:providing a motor of the pump assembly; providing a cylinder head of thepump assembly; providing a cooling air flow to cool both the motor andthe cylinder head; and orienting the motor to such that a substantialportion of the cylinder head can receive at least a portion of coolingair which has not cooled the motor.

The method of cooling a compressor assembly can also have the steps of:providing an air ducting shroud having a plurality of conduits; andfeeding a cooling air through the plurality of conduits to cool a pumpassembly having the motor.

A compressor assembly can have a means for directing a plurality ofcooling air flows to cool a pump assembly of the compressor assembly;and a means for dampening a noise from a compressor assembly to a soundlevel of 75 dBA or less.

The compressor can have a means for directing a cooling air flow to acylinder head of the pump assembly from a fan, and a means for directinga cooling air flow from the fan to a motor of the pump assembly.

The compressor can have a means for directing a cooling air flow to acylinder of the pump assembly.

The compressor can have a means for partitioning chambers within thecompressor assembly such that at least one chamber has at least aportion of trapped air.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention in its several aspects and embodiments solves theproblems discussed above and significantly advances the technology ofcompressors. The present invention can become more fully understood fromthe detailed description and the accompanying drawings, wherein:

FIG. 1 is a perspective view of a compressor assembly;

FIG. 2 is a front view of internal components of the compressorassembly;

FIG. 3 is a front sectional view of the motor and fan assembly;

FIG. 4 is a pump-side view of components of the pump assembly;

FIG. 5 is a fan-side perspective of the compressor assembly;

FIG. 6 is a rear perspective of the compressor assembly;

FIG. 7 is a rear view of internal components of the compressor assembly;

FIG. 8 is a rear sectional view of the compressor assembly;

FIG. 9 is a top view of components of the pump assembly;

FIG. 10 is a top sectional view of the pump assembly;

FIG. 11 is an exploded view of the air ducting shroud;

FIG. 12 is a rear view of a valve plate assembly;

FIG. 13 is a cross-sectional view of the valve plate assembly;

FIG. 14 is a front view of the valve plate assembly;

FIG. 15A is a perspective view of sound control chambers of thecompressor assembly;

FIG. 15B is a perspective view of sound control chambers having optionalsound absorbers;

FIG. 16A is a perspective view of sound control chambers with an airducting shroud;

FIG. 16B is a perspective view of sound control chambers having optionalsound absorbers;

FIG. 17 is a first table of embodiments of compressor assembly ranges ofperformance characteristics;

FIG. 18 is a second table of embodiments of compressor assembly rangesof performance characteristics;

FIG. 19 is a first table of example performance characteristics for anexample compressor assembly;

FIG. 20 is a second table of example performance characteristics for anexample compressor assembly;

FIG. 21 is a table containing a third example of performancecharacteristics of an example compressor assembly;

FIG. 22 is a view of the intake-side of the fan;

FIG. 23 is a first sectional view of the pump assembly;

FIG. 24 is a second sectional view of the pump assembly;

FIG. 25 is a sectional view of the pump assembly;

FIG. 26 is a sectional view of the motor and cooling air flow paths;

FIG. 27 is a cutaway sectional view of the air ducting shroud andcooling air plow paths;

FIG. 28 illustrates exhaust plow paths;

FIG. 29 is a view of exhaust venting;

FIG. 30 is a cross-sectional view of an exhaust chamber of thecompressor assembly;

FIG. 31 is a front sectional view showing examples of cooling air plowpaths; and

FIG. 32 is a top sectional view showing examples of cooling air plowpaths.

Herein, like reference numbers in one figure refer to like referencenumbers in another figure.

DETAILED DESCRIPTION OF THE INVENTION

The invention relates to a compressor assembly which can compress air,or gas, or gas mixtures, and which has a low noise output, effectivecooling means and high heat transfer. The inventive compressor assemblyachieves efficient cooling of the compressor assembly 20 (FIG. 1) and/orpump assembly 25 (FIG. 2) and/or the components thereof (FIGS. 3 and 4).In an embodiment, the compressor can compress air. In anotherembodiment, the compressor can compress one or more gases, inert gases,or mixed gas compositions. The disclosure herein regarding compressionof air is also applicable to the use of the disclosed apparatus in itsmany embodiments and aspects in a broad variety of services and can beused to compress a broad variety of gases and gas mixtures.

FIG. 1 is a perspective view of a compressor assembly 20 shown accordingto the invention. In an embodiment, the compressor assembly 20 cancompress air, or can compress one or more gases, or gas mixtures. In anembodiment, the compressor assembly 20 is also referred to hearingherein as “a gas compressor assembly” or “an air compressor assembly”.

The compressor assembly 20 can optionally be portable. The compressorassembly 20 can optionally have a handle 29, which optionally can be aportion of frame 10.

In an embodiment, the compressor assembly 20 can have a value of weightbetween 15 lbs and 100 lbs. In an embodiment, the compressor assembly 20can be portable and can have a value of weight between 15 lbs and 50lbs. In an embodiment, the compressor assembly 20 can have a value ofweight between 25 lbs and 40 lbs. In an embodiment, the compressorassembly 20 can have a value of weight of, e.g. 38 lbs, or 29 lbs, or 27lbs, or 25 lbs, or 20 lbs, or less. In an embodiment, frame 10 can havea value of weight of 10 lbs or less. In an embodiment, frame 10 canweigh 5 lbs, or less, e.g. 4 lbs, or 3 lbs, of 2 lbs, or less.

In an embodiment, the compressor assembly 20 can have a front side 12(“front”), a rear side 13 (“rear”), a fan side 14 (“fan-side”), a pumpside 15 (“pump-side”), a top side 16 (“top”) and a bottom side 17(“bottom”).

The compressor assembly 20 can have a housing 21 which can have ends andportions which are referenced herein by orientation consistently withthe descriptions set forth above. In an embodiment, the housing 21 canhave a front housing 160, a rear housing 170, a fan-side housing 180 anda pump-side housing 190. The front housing 160 can have a front housingportion 161, a top front housing portion 162 and a bottom front housingpotion 163. The rear housing 170 can have a rear housing portion 171, atop rear housing portion 172 and a bottom rear housing portion 173. Thefan-side housing 180 can have a fan cover 181 and a plurality of intakeports 182. The compressor assembly can be cooled by air flow provided bya fan 200 (FIG. 3), e.g. cooling air stream 2000 (FIG. 3).

In an embodiment, the housing 21 can be compact and can be molded. Thehousing 21 can have a construction at least in part of plastic, orpolypropylene, acrylonitrile butadiene styrene (ABS), metal, steel,stamped steel, fiberglass, thermoset plastic, cured resin, carbon fiber,or other material. The frame 10 can be made of metal, steel, aluminum,carbon fiber, plastic or fiberglass.

Power can be supplied to the motor of the compressor assembly through apower cord 5 extending through the fan-side housing 180. In anembodiment, the compressor assembly 20 can comprise one or more of acord holder member, e.g. first cord wrap 6 and second cord wrap 7 (FIG.2).

In an embodiment, power switch 11 can be used to change the operatingstate of the compressor assembly 20 at least from an “on” to an “off”state, and vice versa. In an “on” state, the compressor can be in acompressing state (also herein as a “pumping state”) in which it iscompressing air, or a gas, or a plurality of gases, or a gas mixture.

In an embodiment, other operating modes can be engaged by power switch11 or a compressor control system, e.g. a standby mode, or a power savemode. In an embodiment, the front housing 160 can have a dashboard 300which provides an operator-accessible location for connections, gaugesand valves which can be connected to a manifold 303 (FIG. 7). In anembodiment, the dashboard 300 can provide an operator access innon-limiting example to a first quick connection 305, a second quickconnection 310, a regulated pressure gauge 315, a pressure regulator 320and a tank pressure gauge 325. In an embodiment, a compressed gas outletline, hose or other device to receive compressed gas can be connectedthe first quick connection 305 and/or second quick connection 310. In anembodiment, as shown in FIG. 1, the frame can be configured to providean amount of protection to the dashboard 300 from the impact of objectsfrom at least the pump-side, fan-side and top directions.

In an embodiment, the pressure regulator 320 employs a pressureregulating valve. The pressure regulator 320 can be used to adjust thepressure regulating valve 26 (FIG. 7). The pressure regulating valve 26can be set to establish a desired output pressure. In an embodiment,excess air pressure can be can vented to atmosphere through the pressureregulating valve 26 and/or pressure relief valve 199 (FIG. 1). In anembodiment, pressure relief valve 199 can be a spring loaded safetyvalve. In an embodiment, the air compressor assembly 20 can be designedto provide an unregulated compressed air output.

In an embodiment, the pump assembly 25 and the compressed gas tank 150can be connected to frame 10. The pump assembly 25, housing 21 andcompressed gas tank 150 can be connected to the frame 10 by a pluralityof screws and/or one or a plurality of welds and/or a plurality ofconnectors and/or fasteners.

The plurality of intake ports 182 can be formed in the housing 21adjacent the housing inlet end 23 and a plurality of exhaust ports 31can be formed in the housing 21. In an embodiment, the plurality of theexhaust ports 31 can be placed in housing 21 in the front housingportion 161. Optionally, the exhaust ports 31 can be located adjacent tothe pump end of housing 21 and/or the pump assembly 25 and/or the pumpcylinder 60 and/or cylinder head 61 (FIG. 2) of the pump assembly 25. Inan embodiment, the exhaust ports 31 can be provided in a portion of thefront housing portion 161 and in a portion of the bottom front housingportion 163.

The total cross-sectional open area of the intake ports 182 (the sum ofthe cross-sectional areas of the individual intake ports 182) can be avalue in a range of from 3.0 in̂2 to 100 in̂2. In an embodiment, the totalcross-sectional open area of the intake ports 182 can be a value in arange of from 6.0 in̂2 to 38.81 in̂2. In an embodiment, the totalcross-sectional open area of the intake ports 182 can be a value in arange of from 9.8 in̂2 to 25.87 in̂2. In an embodiment, the totalcross-sectional open area of the intake ports 182 can be 12.936 in̂2.

In an embodiment, the cooling gas employed to cool compressor assembly20 and its components can be air (also known herein as “cooling air”).The cooling air can be taken in from the environment in which thecompressor assembly 20 is placed. The cooling air can be ambient fromthe natural environment, or air which has been conditioned or treated.The definition of “air” herein is intended to be very broad. The term“air” includes breathable air, ambient air, treated air, conditionedair, clean room air, cooled air, heated air, non-flammable oxygencontaining gas, filtered air, purified air, contaminated air, air withparticulates solids or water, air from bone dry (i.e. 0.00 humidity) airto air which is supersaturated with water, as well as any other type ofair present in an environment in which a gas (e.g. air) compressor canbe used. It is intended that cooling gases which are not air areencompassed by this disclosure. For non-limiting example, a cooling gascan be nitrogen, can comprise a gas mixture, can comprise nitrogen, cancomprise oxygen (in a safe concentration), can comprise carbon dioxide,can comprise one inert gas or a plurality of inert gases, or comprise amixture of gases.

In an embodiment, cooling air can be exhausted from compressor assembly20 through a plurality of exhaust ports 31. The total cross-sectionalopen area of the exhaust ports 31 (the sum of the cross-sectional areasof the individual exhaust ports 31) can be a value in a range of from3.0 in̂2 to 100 in̂2. In an embodiment, the total cross-sectional openarea of the exhaust ports can be a value in a range of from 3.0 in̂2 to77.62 in̂2. In an embodiment, the total cross-sectional open area of theexhaust ports can be a value in a range of from 4.0 in̂2 to 38.81 in̂2. Inan embodiment, the total cross-sectional open area of the exhaust portscan be a value in a range of from 4.91 in̂2 to 25.87 in̂2. In anembodiment, the total cross-sectional open area of the exhaust ports canbe 7.238 in̂2.

Numeric values and ranges herein, unless otherwise stated, also areintended to have associated with them a tolerance and to account forvariances of design and manufacturing, and/or operational andperformance fluctuations. Thus, a number disclosed herein is intended todisclose values “about” that number. For example, a value X is alsointended to be understood as “about X”. Likewise, a range of Y-Z is alsointended to be understood as within a range of from “about Y-about Z”.Unless otherwise stated, significant digits disclosed for a number arenot intended to make the number an exact limiting value. Variance andtolerance, as well as operational or performance fluctuations, are anexpected aspect of mechanical design and the numbers disclosed hereinare intended to be construed to allow for such factors (in non-limitinge.g., ±10 percent of a given value). This disclosure is to be broadlyconstrued. Likewise, the claims are to be broadly construed in theirrecitations of numbers and ranges.

The compressed gas tank 150 can operate at a value of pressure in arange of at least from ambient pressure, e.g. 14.7 psig to 3000 psig(“psig” is the unit lbf/in̂2 gauge), or greater. In an embodiment,compressed gas tank 150 can operate at 200 psig. In an embodiment,compressed gas tank 150 can operate at 150 psig.

In an embodiment, the compressor has a pressure regulated on/off switchwhich can stop the pump when a set pressure is obtained. In anembodiment, the pump is activated when the pressure of the compressedgas tank 150 falls to 70 percent of the set operating pressure, e.g. toactivate at 140 psig with an operating set pressure of 200 psig (140psig=0.70*200 psig). In an embodiment, the pump is activated when thepressure of the compressed gas tank 150 falls to 80 percent of the setoperating pressure, e.g. to activate at 160 psig with an operating setpressure of 200 psig (160 psig=0.80*200 psig). Activation of the pumpcan occur at a value of pressure in a wide range of set operatingpressure, e.g. 25 percent to 99.5 percent of set operating pressure. Setoperating pressure can also be a value in a wide range of pressure, e.g.a value in a range of from 25 psig to 3000 psig. An embodiment of setpressure can be 50 psig, 75 psig, 100 psig, 150 psig, 200 psig, 250psig, 300 psig, 500 psig, 1000 psig, 2000 psig, 3000 psig, or greaterthan or less than, or a value in between these example numbers.

The compressor assembly 20 disclosed herein in its various embodimentsachieves a reduction in the noise created by the vibration of the airtank while the air compressor is running, in its compressing state(pumping state) e.g. to a value in a range of from 60-75 dBA, or less,as measured by ISO3744-1995. Noise values discussed herein are compliantwith ISO3744-1995. ISO3744-1995 is the standard for noise data andresults for noise data, or sound data, provided in this application.Herein “noise” and “sound” are used synonymously.

The pump assembly 25 can be mounted to an air tank and can be coveredwith a housing 21. A plurality of optional decorative shapes 141 can beformed on the front housing portion 161. The plurality of optionaldecorative shapes 141 can also be sound absorbing and/or vibrationdampening shapes. The plurality of optional decorative shapes 141 canoptionally be used with, or contain at least in part, a sound absorbingmaterial.

FIG. 2 is a front view of internal components of the compressorassembly.

The compressor assembly 20 can include a pump assembly 25. In anembodiment, pump assembly 25 which can compress a gas, air or gasmixture. In an embodiment in which the pump assembly 25 compresses air,it is also referred to herein as air compressor 25, or compressor 25. Inan embodiment, the pump assembly 25 can be powered by a motor 33 (e.g.FIG. 3).

FIG. 2 illustrates the compressor assembly 20 with a portion of thehousing 21 removed and showing the pump assembly 25. In an embodiment,the fan-side housing 180 can have a fan cover 181 and a plurality ofintake ports 182. The cooling gas, for example air, can be fed throughan air inlet space 184 which feeds air into the fan 200 (e.g. FIG. 3).In an embodiment, the fan 200 can be housed proximate to an air intakeport 186 of an air ducting shroud 485.

Air ducting shroud 485 can have a shroud inlet scoop 484. As illustratedin FIG. 2, air ducting shroud 485 is shown encasing the fan 200 and themotor 33 (FIG. 3). In an embodiment, the shroud inlet scoop 484 canencase the fan 200, or at least a portion of the fan and at least aportion of motor 33. In this embodiment, an air inlet space 184 whichfeeds air into the fan 200 is shown. The air ducting shroud 485 canencase the fan 200 and the motor 33, or at least a portion of thesecomponents.

FIG. 2 is an intake muffler 900 which can receive feed air forcompression (also herein as “feed air 990”; e.g. FIG. 8) via the intakemuffler feed line 898. The feed air 990 can pass through the intakemuffler 900 and be fed to the cylinder head 61 via the muffler outletline 902. The feed air 990 can be compressed in pump cylinder 60 bypiston 63. The piston can be provided with a seal which can function,such as slide, in the cylinder without liquid lubrication. The cylinderhead 61 can be shaped to define an inlet chamber 81 (e.g. FIG. 9) and anoutlet chamber 82 (e.g. FIG. 8) for a compressed gas, such as air (alsoknown herein as “compressed air 999” or “compressed gas 999”; e.g. FIG.10). In an embodiment, the pump cylinder 60 can be used as at least aportion of an inlet chamber 81. A gasket can form an air tight sealbetween the cylinder head 61 and the valve plate assembly 62 to preventa leakage of a high pressure gas, such as compressed air 999, from theoutlet chamber 82. Compressed air 999 can exit the cylinder head 61 viaa compressed gas outlet port 782 and can pass through a compressed gasoutlet line 145 to enter the compressed gas tank 150.

As shown in FIG. 2, the pump assembly 25 can have a pump cylinder 60, acylinder head 61, a valve plate assembly 62 mounted between the pumpcylinder 60 and the cylinder head 61, and a piston 63 which isreciprocated in the pump cylinder 60 by an eccentric drive 64 (e.g. FIG.9). The eccentric drive 64 can include a sprocket 49 which can drive adrive belt 65 which can drive a pulley 66. A bearing 67 can beeccentrically secured to the pulley 66 by a screw, or a rod bolt 57, anda connecting rod 69. Preferably, the sprocket 49 and the pulley 66 canbe spaced around their perimeters and the drive belt 65 can be a timingbelt. The pulley 66 can be mounted about pulley centerline 887 andlinked to a sprocket 49 by the drive belt 65 (FIG. 3) which can beconfigured on an axis which is represent herein as a shaft centerline886 supported by a bracket and by a bearing 47 (FIG. 3). A bearing canallow the pulley 66 to be rotated about an axis 887 (FIG. 10) when themotor rotates the sprocket 49. As the pulley 66 rotates about the axis887 (FIG. 10), the bearing 67 (FIG. 2) and an attached end of theconnecting rod 69 are moved around a circular path.

The piston 63 can be formed as an integral part of the connecting rod69. A compression seal can be attached to the piston 63 by a retainingring and a screw. In an embodiment, the compression seal can be asliding compression seal.

A cooling gas stream, such as cooling air stream 2000 (FIG. 3), can bedrawn through intake ports 182 to feed fan 200. The cooling air stream2000 can be divided into a number of different cooling air stream flowswhich can pass through portions of the compressor assembly and exitseparately, or collectively as an exhaust air steam through theplurality of exhaust ports 31. Additionally, the cooling gas, e.g.cooling air stream 2000, can be drawn through the plurality of intakeports 182 and directed to cool the internal components of the compressorassembly 20 in a predetermined sequence to optimize the efficiency andoperating life of the compressor assembly 20. The cooling air can beheated by heat transfer from compressor assembly 20 and/or thecomponents thereof, such as pump assembly 25 (FIG. 3). The heated aircan be exhausted through the plurality of exhaust ports 31.

In an embodiment, one fan can be used to cool both the pump and motor. Adesign using a single fan to provide cooling to both the pump and motorcan require less air flow than a design using two or more fans, e.g.using one or more fans to cool the pump, and also using one or more fansto cool the motor. Using a single fan to provide cooling to both thepump and motor can reduce power requirements and also reduces noiseproduction as compared to designs using a plurality of fans to cool thepump and the motor, or which use a plurality of fans to cool the pumpassembly 25, or the compressor assembly 20.

In an embodiment, the fan blade 205 (e.g. FIG. 3) establishes a forcedflow of cooling air through the internal housing, such as the airducting shroud 485. The cooling air flow through the air ducting shroudcan be a volumetric flow rate having a value of between 25 CFM to 400CFM. The cooling air flow through the air ducting shroud can be avolumetric flow rate having a value of between 45 CFM to 125 CFM.

In an embodiment, the outlet pressure of cooling air from the fan can bein a range of from 1 psig to 50 psig. In an embodiment, the fan 200 canbe a low flow fan with which generates an outlet pressure having a valuein a range of from 1 in of water to 10 psi. In an embodiment, the fan200 can be a low flow fan with which generates an outlet pressure havinga value in a range of from 2 in of water to 5 psi.

In an embodiment, the air ducting shroud 485 can flow 100 CFM of coolingair with a pressure drop of from 0.0002 psi to 50 psi along the lengthof the air ducting shroud. In an embodiment, the air ducting shroud 485can flow 75 CFM of cooling air with a pressure drop of 0.028 psi alongits length as measured from the entrance to fan 200 through the exitfrom conduit 253 (FIG. 7).

In an embodiment, the air ducting shroud 485 can flow 75 CFM of coolingair with a pressure drop of 0.1 psi along its length as measured fromthe outlet of fan 200 through the exit from conduit 253. In anembodiment, the air ducting shroud 485 can flow 100 CFM of cooling airwith a pressure drop of 1.5 psi along its length as measured from theoutlet of fan 200 through the exit from conduit 253. In an embodiment,the air ducting shroud 485 can flow 150 CFM of cooling air with apressure drop of 5.0 psi along its length as measured from the outlet offan 200 through the exit from conduit 253.

In an embodiment, the air ducting shroud 485 can flow 75 CFM of coolingair with a pressure drop in a range of from 1.0 psi to 30 psi across asmeasured from the outlet of fan 200 across the motor 33.

Depending upon the compressed gas output, the design rating of the motor33 and the operating voltage, in an embodiment the motor 33 can operateat a value of rotation (motor speed) between 5,000 rpm and 20,000 rpm.In an embodiment, the motor 33 can operate at a value in a range ofbetween 7,500 rpm and 12,000 rpm. In an embodiment, the motor 33 canoperate at e.g. 11,252 rpm, or 11,000 rpm; or 10,000 rpm; or 9,000 rpm;or 7,500; or 6,000 rpm; or 5,000 rpm. The pulley 66 and the sprocket 49can be sized to achieve reduced pump speeds (also herein as“reciprocation rates”, or “piston speed”) at which the piston 63 isreciprocated. For example, if the sprocket 49 can have a diameter of 1in and the pulley 66 can have a diameter of 4 in, then a motor 33 speedof 14,000 rpm can achieve a reciprocation rate, or a piston speed, of3,500 strokes per minute. In an embodiment, if the sprocket 49 can havea diameter of 1.053 in and the pulley 66 can have a diameter of 5.151in, then a motor 33 speed of 11,252 rpm can achieve a reciprocationrate, or a piston speed (pump speed), of 2,300 strokes per minute.

FIG. 3 is a front sectional view of the motor and fan assembly.

FIG. 3 illustrates the fan 200 and motor 33 covered by air ductingshroud 485. The fan 200 is shown proximate to a shroud inlet scoop 484.

The motor can have a stator 37 with an upper pole 38 around which upperstator coil 40 is wound and/or configured. The motor can have a stator37 with a lower pole 39 around which lower stator coil 41 is woundand/or configured. A shaft 43 can be supported adjacent a first shaftend 44 by a bearing 45 and is supported adjacent to a second shaft end46 by a bearing 47. A plurality of fan blades 205 can be secured to thefan 200 which can be secured to the first shaft end 44. When power isapplied to the motor 33, the shaft 43 rotates at a high speed to in turndrive the sprocket 49 (FIG. 2), the drive belt 65 (FIG. 4), the pulley66 (FIG. 4) and the fan blade 200. In an embodiment, the motor can be anon-synchronous universal motor. In an embodiment, the motor can be asynchronous motor used.

The compressor assembly 20 can be designed to accommodate a variety oftypes of motor 33. The motors 33 can come from different manufacturersand can have horsepower ratings of a value in a wide range from small tovery high. In an embodiment, a motor 33 can be purchased from theexisting market of commercial motors. For example, although the housing21 is compact, in an embodiment it can accommodate a universal motor, orother motor type, rated, for example, at ½ horsepower, at ¾ horsepoweror 1 horsepower by scaling and/or designing the air ducting shroud 485to accommodate motors in a range from small to very large.

FIG. 3 and FIG. 4 illustrate the compression system for the compressorwhich is also referred to herein as the pump assembly 25. The pumpassembly 25 can have a pump 59, a pulley 66, drive belt 65 and drivingmechanism driven by motor 33. The connecting rod 69 can connect to apiston 63 (e.g. FIG. 10) which can move inside of the pump cylinder 60.

In one embodiment, the pump 59 such as “gas pump” or “air pump” can havea piston 63, a pump cylinder 60, in which a piston 63 reciprocates and acylinder rod 69 (FIG. 2) which can optionally be oil-less and which canbe driven to compress a gas, e.g. air. The pump 59 can be driven by ahigh speed universal motor, e.g. motor 33 (FIG. 3), or other type ofmotor.

FIG. 4 is a pump-side view of components of the pump assembly 25. The“pump assembly 25” can have the components which are attached to themotor and/or which serve to compress a gas; which in non-limitingexample can comprise the fan, the motor 33, the pump cylinder 60 andpiston 63 (and its driving parts), the valve plate assembly 62, thecylinder head 61 and the outlet of the cylinder head 782. Herein, thefeed air system 905 system (FIG. 7) is referred to separately from thepump assembly 25.

FIG. 4 illustrates that pulley 66 is driven by the motor 33 using drivebelt 65.

FIG. 4 (also see FIG. 10) illustrates an offset 880 which has a value ofdistance which represents one half (½) of the stroke distance. Theoffset 880 can have a value between 0.25 in and 6 in, or larger. In anembodiment, the offset 880 can have a value between 0.75 in and 3 in. Inan embodiment, the offset 880 can have a value between 1.0 in and 2 in,e.g. 1.25 in. In an embodiment, the offset 880 can have a value of about0.796 in. In an embodiment, the offset 880 can have a value of about 0.5in. In an embodiment, the offset 880 can have a value of about 1.5 in.

A stroke having a value in a range of from 0.50 in and 12 in, or largercan be used. A stroke having a value in a range of from 1.5 in and 6 incan be used. A stroke having a value in a range of from 2 in and 4 incan be used. A stroke of 2.5 in can be used. In an embodiment, thestroke can be calculated to equal two (2) times the offset, for example,an offset 880 of 0.796 produces a stroke of 2(0.796)=1.592 in. Inanother example, an offset 880 of 2.25 produces a stroke of 2(2.25)=4.5in. In yet another example, an offset 880 of 0.5 produces a stroke of2(0.5)=1.0 in.

The compressed air passes through valve plate assembly 62 and into thecylinder head 61 having a plurality of cooling fins 89. The compressedgas is discharged from the cylinder head 61 through the outlet line 145which feeds compressed gas to the compressed gas tank 150.

FIG. 4 also identifies the pump-side of upper motor path 268 which canprovide cooling air to upper stator coil 40 and lower motor path 278which can provide cooling to lower stator coil 41.

FIG. 5 illustrates tank seal 600 providing a seal between the housing 21and compressed gas tank 150 viewed from fan-side 14. FIG. 5 is afan-side perspective of the compressor assembly 20. FIG. 5 illustrates afan-side housing 180 having a fan cover 181 with intake ports 182. FIG.5 also shows a fan-side view of the compressed gas tank 150. Tank seal600 is illustrated sealing the housing 21 to the compressed gas tank150. Tank seal 600 can be a one piece member or can have a plurality ofsegments which form tank seal 600.

FIG. 6 is a rear-side perspective of the compressor assembly 20. FIG. 6illustrates a tank seal 600 sealing the housing 21 to the compressed gastank 150.

FIG. 7 is a rear view of internal components of the compressor assembly.In this sectional view, in which the rear housing 170 is not shown, thefan-side housing 180 has a fan cover 181 and intake ports 182. Thefan-side housing 180 is configured to feed air to air ducting shroud485. Air ducting shroud 485 has shroud inlet scoop 484 and conduit 253which can feed a cooling gas, such as air, to the cylinder head 61 andpump cylinder 60.

FIG. 7 also provides a view of the feed air system 905. The feed airsystem 905 can feed a feed air 990 through a feed air port 952 forcompression in the pump cylinder 60 of pump assembly 25. The feed airport 952 can optionally receive a clean air feed from an inertia filter949 (FIG. 8). The clean air feed can pass through the feed air port 952to flow through an air intake hose 953 and an intake muffler feed line898 to the intake muffler 900. The clean air can flow from the intakemuffler 900 through muffler outlet line 902 and cylinder head hose 903to feed pump cylinder head 61. Noise can be generated by the compressorpump, such as when the piston forces air in and out of the valves ofvalve plate assembly 62. The intake side of the pump can provide a pathfor the noise to escape from the compressor which intake muffler 900 canserve to muffle.

The filter distance 1952 between an inlet centerline 1950 of the feedair port 952 and a scoop inlet 1954 of shroud inlet scoop 484 can varywidely and have a value in a range of from 0.5 in to 24 in, or evengreater for larger compressor assemblies. The filter distance 1952between inlet centerline 1950 and inlet cross-section of shroud inletscoop 484 identified as scoop inlet 1954 can be e.g. 0.5 in, or 1.0 in,or 1.5 in, or 2.0 in, or 2.5 in, or 3.0 in, or 4.0 in, or 5.0 in or 6.0in, or greater. In an embodiment, the filter distance 1952 between inletcenterline 1950 and inlet cross-section of shroud inlet scoop 484identified as scoop inlet 1954 can be 1.859 in. In an embodiment, theinertia filter can have multiple inlet ports which can be located atdifferent locations of the air ducting shroud 485. In an embodiment, theinertial filter is separate from the air ducting shroud and its feed isderived from one or more inlet ports.

FIG. 7 illustrates that compressed air can exit the cylinder head 61 viathe compressed gas outlet port 782 and pass through the compressed gasoutlet line 145 to enter the compressed gas tank 150. FIG. 7 also showsa rear-side view of manifold 303.

FIG. 8 is a rear sectional view of the compressor assembly 20. FIG. 8illustrates the fan cover 181 having a plurality of intake ports 182. Aportion of the fan cover 181 can be extended toward the shroud inletscoop 484, e.g. the rim 187. In this embodiment, the fan cover 181 has arim 187 which can eliminate a visible line of sight to the air inletspace 184 from outside of the housing 21. In an embodiment, the rim 187can cover or overlap an air space 188. FIG. 8 illustrates an inertiafilter 949 having an inertia filter chamber 950 and air intake path 922.

In an embodiment, the rim 187 can extend past the air inlet space 184and overlaps at least a portion of the shroud inlet scoop 484. In anembodiment, the rim 187 does not extend past and does not overlap aportion of the shroud inlet scoop 484 and the air inlet space 184 canhave a width between the rim 187 and a portion of the shroud inlet scoop484 having a value of distance in a range of from 0.1 in to 2 in, e.g.0.25 in, or 0.5 in. In an embodiment, the air ducting shroud 485 and/orthe shroud inlet scoop 484 can be used to block line of sight to the fan200 and the pump assembly 25 in conjunction with or instead of the rim187.

The inertia filter 949 can provide advantages over the use of a filtermedia which can become plugged with dirt and/or particles and which canrequire replacement to prevent degrading of compressor performance.Additionally, filter media, even when it is new, creates a pressure dropand can reduce compressor performance.

Air must make a substantial change in direction from the flow of coolingair to become compressed gas feed air to enter and pass through the feedair port 952 to enter the air intake path 922 from the inertia filterchamber 950 of the inertia filter 949. Any dust and other particlesdispersed in the flow of cooling air have sufficient inertia that theytend to continue moving with the cooling air rather than changedirection and enter the air intake path 922.

FIG. 8 also shows a section of a dampening ring 700. The dampening ring700 can optionally have a cushion member 750, as well as optionally afirst hook 710 and a second hook 720.

FIG. 9 is a top view of the components of the pump assembly 25.

Pump assembly 25 can have a motor 33 which can drive the shaft 43 whichcauses a sprocket 49 to drive a drive belt 65 to rotate a pulley 66. Thepulley 66 can be connected to and can drive the connecting rod 69 whichhas a piston 63 (FIG. 2) at an end. The piston 63 can compress a gas inthe pump cylinder 60 pumping the compressed gas through the valve plateassembly 62 into the cylinder head 61 and then out through a compressedgas outlet port 782 through an outlet line 145 and into the compressedgas tank 150.

FIG. 9 also shows a pump 91. Herein, pump 91 collectively refers to acombination of parts including the cylinder head 61, the pump cylinder60, the piston 63 and the connecting rod having the piston 63, as wellas the components of these parts.

FIG. 10 is a top sectional view of the pump assembly 25. FIG. 10 alsoshows a shaft centerline 886, as well as pulley centerline 887 and a rodbolt centerline 889 of a rod bolt 57. FIG. 10 illustrates an offset 880which can be a dimension having a value in the range of 0.5 in to 12 in,or greater. In an embodiment, the stroke can be 1.592 in, from an offset880 of 0.796 in. FIG. 10 also shows air inlet chamber 81.

FIG. 11 illustrates an exploded view of the air ducting shroud 485. Inan embodiment, the air ducting shroud 485 can have an upper ductingshroud 481 and a lower ducting shroud 482. In the example of FIG. 11,the upper ducting shroud 481 and the lower ducting shroud 482 can be fittogether to shroud the fan 200 and the motor 33 and can create air ductsfor cooling pump assembly 25 and/or the compressor assembly 20. In anembodiment, the air ducting shroud 485 can also be a motor cover formotor 33. The upper air ducting shroud 481 and the lower air ductingshroud 482 can be connected by a broad variety of means which caninclude snaps and/or screws.

FIG. 12 is a rear-side view of a valve plate assembly. A valve plateassembly 62 is shown in detail in FIGS. 12, 13 and 14.

The valve plate assembly 62 of the pump assembly 25 can include airintake and air exhaust valves. The valves can be of a reed, flapper,one-way or other type. A restrictor can be attached to the valve plateadjacent the intake valve. Deflection of the exhaust valve can berestricted by the shape of the cylinder head which can minimize valveimpact vibrations and corresponding valve stress.

The valve plate assembly 62 has a plurality of intake ports 103 (fiveshown) which can be closed by the intake valves 96 (FIG. 14) which canextend from fingers 105 (FIG. 13). In an embodiment, the intake valves96 can be of the reed or “flapper” type and are formed, for example,from a thin sheet of resilient stainless steel. Radial fingers 113 (FIG.12) can radiate from a valve finger hub 114 to connect the plurality ofvalve members 104 of intake valves 96 and to function as return springs.A rivet 107 secures the hub 106 (e.g. FIG. 13) to the center of thevalve plate 95. An intake valve restrictor 108 can be clamped betweenthe rivet 107 and the hub 106. The surface 109 terminates at an edge 110(FIGS. 13 and 14). When air is drawn into the pump cylinder 60 during anintake stroke of the piston 63, the radial fingers 113 can bend and theplurality of valve members 104 separate from the valve plate assembly 62to allow air to flow through the intake ports 103.

FIG. 13 is a cross-sectional view of the valve plate assembly and FIG.14 is a front-side view of the valve plate assembly. The valve plateassembly 62 includes a valve plate 95 which can be generally flat andwhich can mount a plurality of intake valves 96 (FIG. 14) and aplurality of outlet valves 97 (FIG. 12). In an embodiment, the valveplate assembly 62 (FIGS. 10 and 12) can be clamped to a bracket byscrews which can pass through the cylinder head 61 (e.g. FIG. 2), thegasket and a plurality of through holes 99 in the valve plate assembly62 and engage a bracket. A valve member 112 of the outlet valve 97 cancover an exhaust port 111. A cylinder flange and a gas tight seal can beused in closing the cylinder head assembly. In an embodiment, a flangeand seal can be on a cylinder side (herein front-side) of a valve plateassembly 62 and a gasket can be between the valve plate assembly 62 andthe cylinder head 61.

FIG. 14 illustrates the front side of the valve plate assembly 62 whichcan have a plurality of exhaust ports 111 (three shown) which arenormally closed by the outlet valves 97. A plurality of a separatecircular valve member 112 can be connected through radial fingers 113(FIG. 12) which can be made of a resilient material to a valve fingerhub 114. The valve finger hub 114 can be secured to the rear side of thevalve plate assembly 62 by the rivet 107. Optionally, the cylinder head61 can have a head rib 118 (FIG. 13) which can project over and can bespaced a distance from the valve members 112 to restrict movement of theexhaust valve members 112 and to lessen and control valve impactvibrations and corresponding valve stress.

FIG. 15A is a perspective view of a plurality of sound control chambersof an embodiment of the compressor assembly 20. FIG. 15A illustrates anembodiment having four (4) sound control chambers. The number of soundcontrol chambers can vary widely in a range of from one to a largenumber, e.g. 25, or greater. In a non-limiting example, in anembodiment, a compressor assembly 20 can have a fan sound controlchamber 550 (also herein as “fan chamber 550”), a pump sound controlchamber 491 (also herein as “pump chamber 491”), an exhaust soundcontrol chamber 555 (also herein as “exhaust chamber 555”), and an uppersound control chamber 480 (also herein as “upper chamber 480”).

FIG. 15B is a perspective view of sound control chambers having optionalsound absorbers. The optional sound absorbers can be used to line theinner surface of housing 21, as well as both sides of partitions whichare within the housing 21 of the compressor assembly 20.

FIG. 16A is a perspective view of sound control chambers with an airducting shroud 485. FIG. 16A illustrates the placement of air ductingshroud 485 in coordination with for example the fan chamber 550, thepump sound control chamber 491, the exhaust sound control chamber 555,and the upper sound control chamber 480.

FIG. 16B is a perspective view of sound control chambers having optionalsound absorbers. The optional sound absorbers can be used to line theinner surface of housing 21, as well as both sides of partitions whichare within the housing 21 of compressor assembly 20.

FIG. 17 is a first table of embodiments of compressor assembly range ofperformance characteristics. The compressor assembly 20 can have valuesof performance characteristics as recited in FIG. 17 which are withinthe ranges set forth in FIG. 17.

FIG. 18 is a second table of embodiments of ranges of performancecharacteristics for the compressor assembly 20. The compressor assembly20 can have values of performance characteristics as recited in FIG. 18which are within the ranges set forth in FIG. 18.

The compressor assembly 20 achieves efficient heat transfer. The heattransfer rate can have a value in a range of from 25 BTU/min to 1000BTU/min. The heat transfer rate can have a value in a range of from 90BTU/min to 500 BTU/min. In an embodiment, the compressor assembly 20 canexhibit a heat transfer rate of 200 BTU/min. The heat transfer rate canhave a value in a range of from 50 BTU/min to 150 BTU/min. In anembodiment, the compressor assembly 20 can exhibit a heat transfer rateof 135 BTU/min. In an embodiment, the compressor assembly 20 exhibited aheat transfer rate of 84.1 BTU/min.

The heat transfer rate of a compressor assembly 20 can have a value in arange of 60 BTU/min to 110 BTU/min. In an embodiment of the compressorassembly 20, the heat transfer rate can have a value in a range of 66.2BTU/min to 110 BTU/min; or 60 BTU/min to 200 BTU/min.

The compressor assembly 20 can have noise emissions reduced by, forexample, a slower fan and/or slower motor speeds, use of a check valvemuffler, use of tank vibration dampeners, use of tank sound dampeners,use of a tank dampening ring, use of tank vibration absorbers to dampennoise to and/or from the tank walls which can reduce noise. In anembodiment, a two stage intake muffler can be used on the pump. Ahousing having reduced or minimized openings can reduce noise from thecompressor assembly. As disclosed herein, the elimination of line ofsight to the fan and other components as attempted to be viewed fromoutside of the compressor assembly 20 can reduce noise generated by thecompressor assembly. Additionally, routing cooling air through ducts,using foam lined paths and/or routing cooling air through tortuous pathscan reduce noise generation by the compressor assembly 20.

Additionally, noise can be reduced from the compressor assembly 20 andits sound level lowered by one or more of the following: employingslower motor speeds, using a check valve muffler and/or using a materialto provide noise dampening of the housing 21 and its partitions and/orthe compressed air tank 150 heads and shell. Other noise dampeningfeatures can include one or more of the following and be used with orapart from those listed above: using a two-stage intake muffler in thefeed to a feed air port 952, elimination of line of sight to the fanand/or other noise generating parts of the compressor assembly 20, aquiet fan design and/or routing cooling air routed through a tortuouspath which can optionally be lined with a sound absorbing material, suchas a foam. Optionally, fan 200 can be a fan which is separate from theshaft 43 and can be driven by a power source which is not shaft 43.

In an example, an embodiment of compressor assembly 20 achieved adecibel reduction of 7.5 dBA. In this example, noise output whencompared to a pancake compressor assembly was reduced from about 78.5dBA to about 71 dBA.

Example 1

FIG. 19 is a first table of example performance characteristics for anexample embodiment. FIG. 19 contains combinations of performancecharacteristics exhibited by an embodiment of compressor assembly 20.

Example 2

FIG. 20 is a second table of example performance characteristics for anexample embodiment. FIG. 20 contains combinations of further performancecharacteristics exhibited by an embodiment of compressor assembly 20.

Example 3

FIG. 21 is a table containing a third example of performancecharacteristics of an example compressor assembly 20. In the Example ofFIG. 21, a compressor assembly 20, having an air ducting shroud 485, adampening ring 700, an intake muffler 900, four sound control chambers,a fan cover, four foam sound absorbers and a tank seal 600 exhibited theperformance values set forth in FIG. 21.

The compressor assembly 20, which is driven by an electric motor, cangenerate heat in the motor windings, as well as in the pump cylinder 60where the air is compressed. Performance can be enhanced and efficiencygained by dissipating heat produced in the motor 33 and pump cylinder60. Heat dissipation, can be achieved by forced air cooling. In anembodiment, forced air cooling is achieved by a cooling air flow fromthe fan 200.

The air ducting shroud 485 can be used to provide a flow of cooling gas,such as air, to the pump assembly 25 which can have a motor 33, a pump91 (FIG. 9) and the fan 200. The pump assembly 25 can compress a gassuch as air. The air ducting shroud 485 can provide ducted air flowwhich can cool both the pump 91 and motor 33 efficiently. In anembodiment, the air ducting shroud 485 can be used to form one duct or aplurality of ducts which can direct cooling air from the fan 200 to oneor a plurality of components of the pump assembly 25, such at to thepump 91 and motor 33.

In an embodiment, the motor 33 can be positioned to place the motorfield windings, such as upper stator coil 40 and lower stator coil 41,at an orientation orthogonal to the cylinder head 61 (FIG. 27) to notsubstantially interfere with, or cause undesired choking, or competefor, cooling air flow to the cylinder head 61. The orientation of thefield windings eliminates the need for these components to compete forthe same cooling air. An orientation in which the motor field windingsand/or motor do not substantially interfere with, or cause undesiredchoking of, or fight for, cooling air flow to the cylinder head 61achieves efficient heat transfer and cooling air flow to portions of thepump assembly 25, such as the motor 33 and the cylinder head 61.Orienting the motor to allow an increased air flow to the head increasesheat transfer and cooling to the cylinder head 61 and/or pump cylinder60 and/or pump 91.

In an embodiment, the above-mentioned advantages can be achieved byarranging the motor field windings, such as the upper stator coil 40 andthe lower stator coil 41, so they are offset from and/or not lined upwith the cylinder head 61 (FIG. 27). Offsetting of the motor fieldwindings from the cylinder head 61 can at least in part eliminateblocking or choking of the cylinder head 61 from cooling air flow. Suchoffsetting can allow ample cooling air flow to the motor field windingsand the pump 91 concurrently. In this arrangement, both the pump andmotor can be cooled by cooling air flow from a single fan 200.Additionally, this configuration allows for the use of a single fanhaving a low rate of flow to cool both of the pump 91 and the motor 33,and/or optionally the pump assembly 25. In an embodiment, the pumpassembly 25 can be cooled by a single fan 200.

When mounting an air compressor in a housing, adequate cooling canaffect the operating life of a compressor assembly 20 and the motor 33.Sources of heat in the motor 33 include but are not limited to thecommutator 51 (FIG. 3), the first stator coil 40, the second stator coil41, and coils in the rotor 50 (FIG. 3). Heat can be produced by the airas it is compressed in pump 91 and by the drive belt 65 (FIG. 3). Thefan blade 205 can establish a forced flow of cooling air through thehousing 21. According to one feature of the invention, the air ductingshroud 485 can separate the cooling air into a number of streams to coolthese components of the compressor assembly 20.

In an embodiment, housing 21 can encase an air ducting shroud 485 (FIG.2) which can have a number of pathways for guiding the cooling air fromthe fan 200. In a non-limiting example, the compressor assembly 20cooling air stream 2000 is drawn into the fan 200 through the pluralityof intake slots 182, and is driven into the compressor assembly as faneffluent stream 193 by the plurality of fan blades 205.

In an embodiment, the compressor assembly 20 uses pathways to direct theflow of cooling air to locations, such as for example to cool the pump91 and the motor 33. Cooling the pump 91 and the motor 33 allows each tooperate with improved efficiency. A pump cooling path for the pumpassembly 25 can be created by forming an internal cast opening in theair ducting shroud 485.

In an embodiment, the cooling air flow can be divided into a number ofcooling air flows (also herein as “segments”). In an embodiment, theflow paths can be of a size which reduces back pressure and avoidschoking cooling air flow.

In an embodiment, the fan effluent stream 193 cooling air flow can bedivided into two cooling air flows, a first cooling air flow (alsoherein as “segment 1”) and a second cooling air flow (also herein as“segment 2”). In the two cooling air flow embodiment, one of the coolingair flows can flow across the bottom field winding and the other coolingair flow can flow across the top field winding and the cylinder head 61area of pump 91.

FIG. 22 is another embodiment in which the cooling air flow can bedivided into three cooling air flows (three cooling air segments).

The example of FIG. 22 illustrates a fan 200 which can feed ambient airas cooling air into the air ducting shroud 485. The cooling air flow canbe divided into at least three (3) cooling air flows. In an embodiment,the cooling air flow can be divided into a first cooling air flow (alsoherein as “segment 1”), a second cooling air flow (also herein as“segment 2”) and a third cooling air flow (also herein as “segment 3”).Respectively, FIG. 22 designates these cooling air flowsrepresentatively as “1”, “2” and “3”.

As illustrated in FIG. 22, the cooling air stream 2000 which passesthrough the fan 200 becomes the fan effluent stream 193 (FIG. 3) whichcan be separated internally into a plurality of cooling air flows, e.g.three or more cooling air flows stream. In FIG. 22, the fan effluentstream 193 can be partitioned into at least three streams as shown bythe partition lines and three stream partition designations, i.e. “1”,“2” and “3”. In an embodiment, a cooling air flow 1 (“segment 1” of FIG.22) can at least in part feed an upper motor stream 270 (FIG. 23). Acooling air flow 2 (“segment 2” of FIG. 22) can at least in part feed alower motor stream 280 (FIG. 27). A cooling air flow 3 (“segment 3” ofFIG. 22) can at least in part feed a pump stream 254 (FIG. 23).

The partition lines shown in FIG. 22 are exemplary in nature and theactual flow division of the fan caused by the air ducting shroud 485will occur in accordance with the mechanical design of the air ductingshroud 485 and the fluid dynamics of the flow streams and the open pathswhich can exist.

In the embodiment disclosed herein, the cooling design of the compressorassembly 20 can control a temperature rise of the motor that meets orexceeds that required by UL 1450 (which is a standard set by UL LLC, 333Pfingsten Road Northbrook, Ill. 60062-2096).

FIG. 23 is a first sectional view of the pump assembly showing the uppermotor stream 270 cooling the fan-side of the upper stator coil 40. Thelower motor stream 280 is also illustrated cooling the fan-side of thelower stator coil 41.

Electricity flowing through the field windings of the motor 33 generatesheat in the motor. The air ducting shroud 485 can direct the cooling airinto the areas heated by the heat generated in the motor 33. The sidesof the motor that do not contain field windings can be blocked off(fully or partially depending on need) to force more air across theother two sides of the motor where the field windings are located, aswell as into conduit 253. In this example, fan effluent stream 193 issplit into three cooling air flow paths and each flow path is directedto one of at least three areas that need cooling, such as the two sidesof the motor having stator coils (upper stator coil 40 and lower statorcoil 41) and the pump 91 area having cylinder head 61 and pump cylinder60. In an embodiment, the stream which can cool the cylinder head 61 canalso cool the pump cylinder 60.

In an embodiment, the upper motor stream 270 can flow across at least aportion of the upper stator coil 40; the lower motor stream 280 can flowacross at least a portion of the lower stator coil 41; and a conduit airstream 254 can flow across the cylinder head 61 and the pump cylinder 60of the pump 91.

FIG. 27 illustrates the upper coil centerline 204 intersecting headcenterline 202 at angle 207 which is 90 degrees. The lower coilcenterline 206 is illustrated to intersect head centerline 202 at angle207 which is 90 degrees. For illustrative purposes, this configurationcan form the triangle 209 among at least a portion of the respectivemotor coils and head centerline 202 as shown in FIG. 27. Suchconfiguration allows for easy passage of cooling air and separation ofthe cooling air blown by the fan.

FIG. 23 illustrates an embodiment having the fan effluent stream 193which is separated into a upper motor stream 270, a lower motor stream280 and a conduit air stream 254. The upper motor stream 270 can flowthrough the upper motor path 268 to cool the upper stator coil 40. Thelower motor stream 280 can flow through lower motor path 278 to cool thelower stator coil 41. The conduit air stream 254 can flow through theconduit 253 to cool the cylinder head 61 and the pump cylinder 60.

FIG. 23 illustrates a front blocking partition 115 which blocks air flowalong the front motor surface 486 of the motor 33. FIG. 23 alsoillustrates a rear blocking partition 116 which blocks air flow alongthe rear motor surface 488 of the motor 33. The blocking partition 115and the blocking partition 116 can provide resistance which can forcethe cooling air to pass through the upper motor path 268 and the lowermotor path 278, as well as through conduit 253 having conduit flow path255.

In the example embodiment of FIG. 23, upper motor path 268 can be apassageway formed from surfaces of the motor 33 and the air ductingshroud 485. For example, upper motor path 268 can have a portion of theupper motor block surface 58 and a portion of the upper inside surface487 of the air ducting shroud 485 (also herein as “motor cover 485”). Inthis example, the lower motor path 278 can be a passageway formed frome.g. a portion of the lower motor block surface 59 and a portion of thelower inside surface 489 of air ducting shroud 485.

In this embodiment, the air ducting shroud 485 can form the conduit 253having the conduit flow path 255 and can have at least a portion whichflows through the conduit 253.

FIG. 24 is a sectional view of a perspective of the fan-side of themotor in which the upper motor stream 270 can flow through the uppermotor path 268, the lower motor stream 280 can flow through the lowermotor path 278 and the conduit air stream 254 can flow the through theconduit 253.

FIG. 24 also is a cross-sectional view of the motor 33 and the conduit253. In the example of FIG. 24, the blocking partitions 115 and theblocking partition 116 can force the cooling air to pass through theupper motor path 268, the lower motor path 278 and the conduit 253. Inthe embodiment illustrated in FIG. 24, the front blocking partition 115and the rear blocking partition 116 are illustrated as blocking the flowof air along the front motor surface 490 and rear motor surface 492. Thefront blocking partition 115 can block the formation of an air flowbetween the front motor surface 490 and the front inside surface 486 ofthe air ducting shroud 485. The rear blocking partition 116 can blockthe formation of air flow between the rear motor surface 492 and therear inside surface 488 of air ducting shroud 485. When the frontblocking partition 115 and the rear blocking partition 116 are used, thefan effluent stream 193 can be partitioned to the cool the motor 33(FIG. 3) and provide flow at least through upper motor path 268, thelower motor path 278 and the conduit flow path 255.

FIG. 25 is a sectional view of the pump assembly 25. The upper motorstream 270 can flow through the upper motor path 268. The lower motorstream 280 can flow through lower motor path 278. The conduit air stream254 can flow through conduit 253 of air ducting shroud 485. In theexample of FIG. 25, the flow of the conduit air stream 254 over cylinderhead 61 can become a head air stream 256 as it contacts and flows acrossthe cylinder head 61.

Optionally, the conduit 253 can extend to cover at least a portion ofcylinder head 61. Optionally, the conduit 253 can be formed to providecooling to at least a portion of the pump 91, such as the pump cylinder60 and/or the cylinder head 61.

As shown in FIG. 26, an upper motor path 268 is formed between the upperstator portion of the motor and the inner diameter of the air ductingshroud 485 and a lower motor path 278 is formed between the lower statorportion of the motor and the inner diameter of the air ducting shroud485. A motor gap 240 can extend in an axial direction through the motor33 between the stator and the rotor. A portion of the air delivered bythe fan blade 205 can flow though the motor air gap 240. In anembodiment, the cooling air can flow along a path in example sequenceover the commutator 51 and brush assembly, then through the motor airgap 240, then over at least a portion of the pump cylinder 60 andthrough the plurality of exhaust slots 31. In an embodiment, this firstflow of air can accept heat transfer from at least the motor 33, andthen optionally at least the pump cylinder 60 and the cylinder head 61.

FIG. 26 is a sectional view of the motor and cooling air flow paths;showing cooling air which can flow through motor air gap 240 and flowacross the upper stator coil 40 and the lower stator coil 41. The fancan direct some air to travel through the motor air gap 240 between thearmature and the electric field to help cool the armature windings.

FIG. 27 is a cutaway sectional view of the air ducting shroud andcooling air flow.

As shown in FIG. 27, the upper motor stream 270 can flow through theupper motor path 268. The lower motor stream 280 can flow through lowermotor path 278. FIG. 27 also illustrates a conduit air stream 254 whichflows through conduit 253. A portion of the conduit air stream 254 canfeed the pump stream 258 which separates from conduit stream 254 to coolthe pump cylinder 60 of the pump 91. FIG. 28 also illustrates that theportion of the conduit air stream which does not become the pump stream258 becomes the head air stream 256 which flows to cool cylinder head61.

FIG. 27 also illustrates that the cylinder air stream 258 can separatefrom the pump air stream 254 into a first cylinder air stream 260 and asecond cylinder air stream 262 to cool pump cylinder 60. The pump stream258 can optionally be split as it passes though a plurality of optionalports. In the example of FIG. 27 pump stream 258 can split into a firstcylinder air stream 260 which can flow through a first cylinder coolingport 261 and a second cylinder air stream 262 can flow through a secondcylinder cooling port 259. The first cylinder air stream 260 and thesecond cylinder air stream 262 can cool at least pump cylinder 60.

In an embodiment, the fan effluent stream 193 can also supply flow to anupper motor stream 270 through upper motor path 268 and a lower motorstream 280 through lower motor path 278.

In an embodiment, the motor can be cooled at least in part by an uppermotor stream 270 which can flow through an upper motor path 268.Additionally, the motor can be cooled at least in part by a lower motorstream 280 which can flow through lower motor path 278.

In an embodiment, at least a portion of the head air stream 256 flowsover the cylinder head 61. Additionally, at least a portion of the pumpcooling path can guide a portion the cooling air over the cylinder head61 and pump cylinder 60. Also, a first cylinder air stream 258 can flowover at least a portion of pump cylinder 60 and can feed at least aportion of second cylinder air stream 262 which can also feed at least aportion of a second cylinder air stream 260 which can flow over at leasta portion of pump cylinder 60.

FIG. 28 illustrates the exhaust flow paths. FIG. 28 is a pump-side viewwhich illustrates the exhaust flow from the head air stream 256 ascylinder head exhaust air stream 296. The head exhaust air stream 296can become an exhaust air stream 299.

FIG. 28 illustrates that the first cylinder air stream 260 (FIG. 28) canbecome a first cylinder exhaust air stream 289 which can become acylinder exhaust air stream 295. The second cylinder air stream 262(FIG. 28) can become a second cylinder exhaust air stream 291 which canbecome a cylinder exhaust air stream 295. The cylinder head exhaust airstream 295 can also become an exhaust air stream 299.

In the example embodiment illustrated in FIG. 28, the upper motor stream270 can flow through the upper motor path 268, then across upper statorcoil 40 and becomes upper winding exhaust 293. The lower motor stream280 can flow through the lower motor path 278, then across lower statorcoil 41 and becomes lower winding exhaust 294.

The upper motor stream 270 can become an upper winding exhaust airstream 293 which can become a windings exhaust air stream 297. The lowermotor stream 280 can become a lower winding exhaust air stream 294 whichcan become a windings exhaust air stream 297. The windings exhaust airstream 297 can become an exhaust air stream 299.

FIG. 28 illustrates the flow of the exhaust air stream 299. In anembodiment, the exhaust air stream 299 is a combined exhaust air streamof the exhausts streams which have passed over portions of the motor orportions of the pump. In an embodiment, the exhaust air stream 299 is acombined exhaust air stream of the exhaust flowing from upper motor path268, lower motor path 278 and conduit 253.

FIG. 29 illustrates a view of exhaust venting. FIG. 29 illustrates thehead exhaust air stream 296 becoming an exhaust air stream 299 andexiting the compressor assembly 20 through a plurality of the exhaustair slots 31. The cylinder exhaust air 295 can become an exhaust airstream 299 and can exit the compressor assembly 20 through the exhaustair slots 31. The windings exhaust air stream 297 can become an exhaustair stream 299 and can exit the compressor assembly 20 through theexhaust air slots 31. Optionally, one or a plurality of louvers 298 canbe used in conjunction with the exhaust air slots 31. The louvers 298can eliminate an operator's line-of-sight to the pump assembly 25 and/orto one or more noise making parts.

FIG. 30 is a cross-sectional view of the exhaust chamber of thecompressor assembly. In the embodiment of FIG. 30, a plurality oflouvers 298 can be used in conjunction with the exhaust air slots 31.

FIG. 31 is a front sectional view showing examples of cooling air plowpaths.

FIG. 32 is a top sectional view showing examples of cooling air plowpaths.

Cooling air can pass on the two sides of the motor with the field coils.Openings can be used to force air across the windings. Air flow can beblocked on the two sides of the motor having no field coils along thosetwo sides. Cooling air from fan can flow across head and cylinder area.

The scope of this disclosure is to be broadly construed. It is intendedthat this disclosure disclose equivalents, means, systems and methods toachieve the devices, designs, operations, control systems, controls,activities, mechanical actions, fluid dynamics and results disclosedherein. For each mechanical element or mechanism disclosed, it isintended that this disclosure also encompasses within the scope of itsdisclosure and teaches equivalents, means, systems and methods forpracticing the many aspects, mechanisms and devices disclosed herein.Additionally, this disclosure regards a compressor and its many aspects,features and elements. Such an apparatus can be dynamic in its use andoperation. This disclosure is intended to encompass the equivalents,means, systems and methods of the use of the compressor assembly and itsmany aspects consistent with the description and spirit of theapparatus, means, methods, functions and operations disclosed herein.The claims of this application are likewise to be broadly construed.

The description of the inventions herein in their many embodiments ismerely exemplary in nature and, thus, variations that do not depart fromthe gist of the invention are intended to be within the scope of theinvention and the disclosure herein. Such variations are not to beregarded as a departure from the spirit and scope of the invention.

It will be appreciated that various modifications and changes can bemade to the above described embodiments of a compressor assembly asdisclosed herein without departing from the spirit and the scope of thefollowing claims.

1. A compressor assembly, comprising: a fan; a pump assembly; an airducting shroud which directs cooling air to a member of the pumpassembly and which is adapted to dampen a noise from the pump assembly;a sound level having a value of 75 dBA or less when the compressor is ina compressing state.
 2. The compressor assembly according to claim 1,wherein the air ducting shroud encases at least a portion of the fan. 3.The compressor assembly according to claim 1, wherein the air ductingshroud encases at least a portion of a motor of the pump assembly. 4.The compressor assembly according to claim 1, wherein the air ductingshroud comprises a conduit which directs a cooling air flow to acylinder head of the pump assembly.
 5. The compressor assembly accordingto claim 1, wherein the air ducting shroud directs a cooling air flow toat least a portion of a motor of the pump assembly.
 6. The compressorassembly according to claim 1, wherein the air ducting shroud directs acooling air flow to at least a portion of a pump of the pump assembly.7. The compressor assembly according to claim 1, wherein the air ductingshroud directs cooling air to at least a portion of a cylinder of thepump assembly.
 8. The compressor assembly according to claim 1, whereinthe air ducting shroud further comprises a conduit adapted to direct acooling air flow to a cylinder head of the pump assembly.
 9. Thecompressor assembly according to claim 1, wherein the air ducting shroudhas at least one partition which directs a cooling air flow.
 10. Thecompressor assembly according to claim 1, wherein the air ducting shroudencases a motor and directs a first cooling air flow to a first statorcoil of a motor and which directs a second cooling air flow to a secondstator of a motor and a third cooling air flow to a cylinder head of thepump assembly.
 11. The compressor assembly according to claim 1, furthercomprising a heat transfer rate from the pump assembly having a value of60 BTU/min or greater when the compressor is in a compressing state. 12.The compressor assembly according to claim 1, further comprising acooling air flow rate having a value of 50 CFM or greater when thecompressor is in a compressing state.
 13. The compressor assemblyaccording to claim 1, further comprising a motor of the pump assemblywith a motor efficiency greater than 45 percent.
 14. A method of coolinga compressor assembly, comprising the steps of: providing a fan;providing a pump assembly; cooling the pump assembly with at least aportion of a cooling air flow provided by the fan when the compressor isin a compressing state; and operating the compressor at a sound level ofless than 75 dBA.
 15. The method of cooling a compressor assemblyaccording to claim 14, further comprising the steps of: providing amotor of the pump assembly; providing a cylinder head of the pumpassembly; providing a cooling air flow to cool both the motor and thecylinder head; and orienting the motor to such that a substantialportion of the cylinder head can receive at least a portion of coolingair which has not cooled the motor.
 16. The method of cooling acompressor assembly according to claim 15, further comprising the stepsof: providing an air ducting shroud having a plurality of conduits,feeding a cooling air through the plurality of conduits to cool a pumpassembly comprising the motor.
 17. A means for cooling a compressorassembly, comprising: a means for directing a plurality of cooling airflows to cool a pump assembly of the compressor assembly; a means fordampening a noise from a compressor assembly to a sound level of 75 dBAor less.
 18. The means for cooling a compressor assembly according toclaim 17, further comprising: a means for directing a cooling air flowto a cylinder head of the pump assembly from a fan; and a means fordirecting a cooling air flow to a motor the pump assembly from the fan.19. The means for cooling a compressor assembly according to claim 17,further comprising: a means for directing a cooling air flow to acylinder of the pump assembly.
 20. The means for cooling a compressorassembly according to claim 17, further comprising: a means forpartitioning chambers within the compressor assembly such that at leastone chamber has at least a portion of trapped air.